GRUNDFOS DATA BOOKLET UPS2 Circulator pumps 50/60 Hz
UPS2 Table of contents 1. Product introduction 3 Type key.................................................................................... 3 Performance range............................................................................ 3 2. Applications 4 UPS replacement.............................................................................. 4 Pumped liquids............................................................................... 4 Control of heating systems...................................................................... 5 Advantages of pump control..................................................................... 5 3. Construction 6 Sectional drawing.............................................................................. 6 Material specification........................................................................... 6 Motor and control box.......................................................................... 6 4. nstallation and startup 7 nstallation................................................................................... 7 Electrical data................................................................................ 7 Startup...................................................................................... 7 Liquid temperature............................................................................. 7 System pressure.............................................................................. 7 nlet pressure................................................................................. 7 Setting the pump.............................................................................. 7 Control of the pump............................................................................ 7 Change of pump performance.................................................................... 8 5. Guide to performance curves 9 Energy labelling............................................................................... 9 Curve conditions.............................................................................. 9 6. Performance curves and technical data 10 UPS2 15-40/60 130, UPS2 25-40/60 130, UPS2 25-40/60 180, UPS2 PH-40/60............................ 10 UPS2 15-50/60 130, UPS2 PH-50/60............................................................. 11 UPS2 25-80 180, UPS2 32-80 180............................................................... 12 7. Accessories 13 nsulating kits................................................................................ 13 ALPHA plugs................................................................................ 13 Union and valve kits........................................................................... 13 8. Product range 14 UPS2...................................................................................... 14 UPS2, United Kingdom........................................................................ 14 UPS2, reland................................................................................ 14 UPS2, BU/RO/GR............................................................................ 14 9. Grundfos Product Center 15 2
UPS2 1 1. Product introduction UPS2 is a complete range of circulator pumps with the following features: integrated differential-pressure control enabling adjustment of pump performance to the actual system requirement motor based on permanent-magnet/compact-rotor technology. The pumps are energy-optimised and comply with the requirements of the EuP directive. The installation of UPS2 will reduce power consumption considerably, reduce noise from thermostatic valves and similar fittings and improve the control of the system. The UPS2 range offers a host of advantages: Energy savings High-efficient permanent-magnet motors. Flexibility Suitable for installation in existing systems. Comfort Low-noise operation. Safety Built-in electrical and thermal protection of the pump. User friendliness Simple setting and operation. Type key Example UPS2 15-40/50/60 130 Pump range Nominal diameter (DN) of inlet and outlet ports [mm] (15 = 1"25 = 1 1/2", PH = pump head only) Maximum head [dm] of the UPS pump types that can be replaced by the UPS2 Port-to-port length [mm] * Exception: UK version, size 15 = 1 1/2". Product introduction Performance range Fig. 1 Performance range TM05 6080 3614 3
2 UPS2 UPS replacement UPS2 is designed specifically for domestic heating systems. The pumps are used primarily for one- and two-pipe heating systems, but are, for example, also suitable for mixing loops in large systems. TM03 3988 4507 Applications 2. Applications Fig. 2 One-pipe heating system UPS2 is the perfect replacement option to optimise efficiency in domestic heating systems. The most modern technology has been used in the development and manufacturing of the UPS2 pumps. With an EE value 0.23, the pump is designed to meet the efficiency demands of the 2015 EuP directive. UPS2 is designed specifically to meet performance and dimensional demands in relation to replacement of existing UPS pumps. UPS2 is available as a pump head (PH version) which can be fitted to the pump housing of existing UPS pumps. We offer this solution for the replacement of all UPS pump types. This is a very time-efficient and simple replacement solution as the pump housing does not need to be removed from the pipework. Design benefits which make UPS2 the ideal replacement pump: direct compatibility compact pump head cable plug integrated in control box performance change in terms of speed setting easy-to-read interface. The table below shows a comparison of the speed setting of an existing UPS pump and a UPS2 pump. Existing pump Head [m] TM03 9889 4507 4 Fig. 3 5 6 Two-pipe heating system 8 Speed setting of existing UPS pump Equivalent speed setting of UPS2,, See section Control of the pump, page 7, for further details. TM03 9890 4507 Pumped liquids Fig. 4 4 Underfloor heating system The pump is suitable for clean, thin, non-aggressive and non-explosive liquids, not containing solid particles, fibres or mineral oil. The pump must not be used for the transfer of flammable liquids, such as diesel oil, petrol and similar liquids.
UPS2 2 Control of heating systems The heating required in a building varies greatly during the day due to changing outdoor temperatures, solar radiation and heat emanating from human beings, electric appliances, etc. Add to this that the need for heating may vary from one section of the building to another and that the thermostatic valves of some radiators may be turned down by the users. These circumstances will cause an uncontrolled pump to produce a too high differential pressure when the heating demand is low. Possible consequences: too high energy consumption irregular control of the system noise in thermostatic valves and similar fittings. UPS2 automatically controls the differential pressure by adjusting the pump performance to the actual heating demand, without the use of external components. Advantages of pump control n UPS2, control is effected by adapting the differential pressure to the flow. Contrary to an uncontrolled pump, the proportional-pressure-controlled UPS2 pump reduces the differential pressure in case of falling heating demand. f the heating demand falls, for instance due to solar radiation, the radiator valves will close, and, for the uncontrolled pump, the flow resistance of the system will rise for instance from A 1 to A 2. n a heating system with an uncontrolled pump, this situation will cause a pressure rise in the system by ΔH 1. H 2 A 2 1 ΔH 1 A 1 Fig. 6 Pump in proportional-pressure control mode n a system with an uncontrolled pump, a pressure rise will often cause flow-generated noise in the thermostatic valves. This noise will be reduced considerably with UPS2. UPS2 has three proportional-pressure curves which are close to the best efficiency point. As the pump is the obvious UPS replacement option, the three fixed speeds are under normal conditions the best choice from a user s point of view. The pump has the following control modes: proportional-pressure control constant-curve control. Proportional-pressure control Proportional-pressure control adjusts the pump performance to the actual heat demand in the system, but the pump performance follows the selected performance curve, PP1, PP2 or PP3. See fig. 7 where PP2 has been selected. See Change of pump performance for further information. H Fig. 7 H A 2 1 ΔH 2 PP3 Q 2 A 3 PP2 Q 1 Three proportional-pressure curves/settings A 1 Q PP1 Q TM01 9120 5002 TM06 1830 3114 Applications Fig. 5 Q 2 Uncontrolled pump n a system with a UPS2 pump, the pressure will be reduced by ΔH 2. Q 1 Q TM01 9119 5002 Constant-curve control At constant-curve/constant-speed operation, the pump runs at a constant speed, independent of the actual flow demand in the system. The pump performance follows the selected performance curve,, or. See fig. 8 where has been selected. See Change of pump performance for further information. H Q TM05 3068 0912 Fig. 8 Three constant-curve/constant-speed settings 5
3 UPS2 Construction 3. Construction UPS2 is designed for long and trouble-free operation due to the canned-rotor type, i.e. pump and motor form an integral unit without shaft seal and with only two gaskets for sealing. The bearings are lubricated by the pumped liquid. These constructions ensure maintenance-free operation. The pumps are characterised by the following: Permanent-magnet/compact-stator motor contributing to high efficiency and high starting torque. Ceramic shaft and radial bearings contributing to long life. Carbon thrust bearing contributing to long life Stainless-steel rotor can, bearing plate and rotor cladding contributing to corrosion-free long life. Composite impeller contributing to corrosion-free long life. Design featuring pump head with integrated control box and control panel or the compact UPS2 design. Sectional drawing Motor and control box The motor is a 4-pole synchronous permanent-magnet motor. The pump controller is incorporated in the control box, which is fitted to the stator housing with screws. Control panel Fig. 10 Push-button position TM05 5380 1012 TM05 5379 1012 UPS2 has a push-button (pos. 1) for selection of pump setting and light fields for indication of the selected pump setting. See fig. 10. The light is on when the power supply has been switched on. Control box positions Fig. 9 Position numbers Material specification Pos. Description Material EN 1 9 11 Controller complete Composite, PC AS/ ASTM Rotor can Stainless steel 1.4301 304 Radial bearing Ceramics Shaft Ceramics Rotor cladding Stainless steel 1.4301 304 Thrust bearing Carbon 12 Thrust bearing retainer EPDM rubber 13 Bearing plate Stainless steel 1.4301 304 16 mpeller Composite, PP or PES 18 Pump housing Cast iron EN-JL 1020 A48-25 Gaskets EPDM rubber Fig. 11 Possible control box positions TM05 5381 1012 6
UPS2 4 4. nstallation and startup nstallation n most cases, the installation of UPS2 is reduced to the mechanical installation and the connection to the power supply. The pump must always be installed with horizontal motor shaft. System pressure PN 10: Maximum 1.0 MPa (10 bar). nlet pressure To avoid cavitation noise and damage to the pump, the following minimum pressures are required at the pump inlet port. nstallation and startup Fig. 12 Horizontal motor shaft Electrical data Supply voltage 1 x 230 V - 10 %/+ 10 %, 50/60 Hz, PE. Motor protection The pump requires no external motor protection. Enclosure class P44. nsulation class F. Relative air humidity Maximum 95 %. Ambient temperature 0-55 C. Temperature class TF95 to CEN 335-2-51. EMC (electromagnetic compatibility) EN 61000-6-2 and EN 61000-6-3. Sound pressure level 43 db(a). Startup The pump must not be started until the system has been filled with liquid and vented. Furthermore, the required minimum inlet pressure must be available at the pump inlet. The system cannot be vented through the pump. The pump is self-venting and does not require venting before startup. TM05 5382 3612 Liquid temperature 75 C 90 C 110 C 0.5 m head 2.8 m head 10.8 m head Setting the pump Using the push-button on the control box, you can set the electronically controlled pump to the following: three fixed-speed curves three proportional-pressure curves. Factory setting The UPS2 pump has been factory-set to speed. See fig. 14. At this setting, the pump will deliver its maximum performance, but the setting can be changed so that it matches the actual heating demand. Control of the pump The pump setting can be changed with a single press on the push-button. Figure 13 illustrates how UPS2 changes between the three speeds. This setting is indicated by a steady green light. When you press the button for five seconds, the pump will change from fixed-speed operation to proportionalpressure control. Figure 13 also illustrates how UPS2 changes between the three proportional-pressure curves. This setting is indicated by a flashing green light. See section Change of pump performance, page 8, for further details. = / / Liquid temperature = / / To avoid condensation in the control box and stator, the liquid temperature must always be higher than the ambient temperature. See table below. Ambient temperature [ C] Minimum [ C] Liquid temperature Maximum [ C] 0 2 95 10 10 95 20 20 95 30 30 95 35 35 95 40 40 95 (5 (5 sec.) sec.) (5 (5 sec.) sec.) (5 sec.) Fig. 13 Control modes TM06 9074 2617 7
4 UPS2 nstallation and startup Change of pump performance The pump performance (flow and head) can be changed by pressing the control box push-button as indicated in fig. 13 and the table below. H H Fig. 14 Pump setting in relation to performance Q Q TM06 1831 3114 Setting Pump curve Function Lowest proportionalpressure curve PP1 ntermediate proportional-pressure curve PP2 Highest proportionalpressure curve PP3 Speed Speed Speed The duty point of the pump will move up or down on the lowest proportional-pressure curve, depending on the heat demand in the system. See fig. 14. The head (pressure) is reduced at falling heat demand and increased at rising heat demand. The duty point of the pump will move up or down on the intermediate proportional-pressure curve, depending on the heat demand in the system. See fig. 14. The head (pressure) is reduced at falling heat demand and increased at rising heat demand. The duty point of the pump will move up or down on the highest proportional-pressure curve, depending on the heat demand in the system. See fig. 14. The head (pressure) is reduced at falling heat demand and increased at rising heat demand. The pump runs at a constant speed and consequently on a constant curve. n speed, the pump is set to run on the maximum curve under all operating conditions. See fig. 14. Quick venting of the pump can be obtained by setting the pump to speed for a short period. The pump runs at a constant speed and consequently on a constant curve. n speed, the pump is set to run on the intermediate curve under all operating conditions. See fig. 14. The pump runs at a constant speed and consequently on a constant curve. n speed, the pump is set to run on the minimum curve under all operating conditions. See fig. 14. 8
UPS2 5 5. Guide to performance curves Energy labelling The UPS2 is energy-optimised and complies with the EuP Directive (Commission Regulation (EC) No 641/ 2009) which has been effective since 1 January 2013. For more information about the new energy directive, please visit: Energy.grundfos.com TM05 2683 0412 Guide to performance curves Curve conditions The guidelines below apply to the performance curves on the following pages: Test liquid: airless water. The curves apply to a density of ρ = 983.2 kg/m 3 and a liquid temperature of 60 C. All curves show average values and should not be used as guarantee curves. f a specific minimum performance is required, individual measurements must be made. The curves for speeds, and are marked. The curves apply to a kinematic viscosity of = 0.474 mm 2 /s (0.474 cst). The conversion between head H [m] and pressure p [kpa] has been made for water with a density of ρ = 1000 kg/m 3. For liquids with other densities, for example hot water, the outlet pressure is proportional to the density. The EE values for UPS2 pumps are far below the EuP 2013 value and comply with the requirements for 2015. See fig. 15. ndex 100 90 80 70 60 50 40 30 EE = 0.27 EE = 0.23 EE = 0.23 20 10 0 EuP 2013 EuP 2015 UPS2 TM05 7834 1613 Fig. 15 EE limits and the current positioning of the UPS2 9
6 Performance curves and technical data 6. Performance curves and technical data UPS2 15-40/60 130, UPS2 25-40/60 130, UPS2 25-40/60 180, UPS2 PH-40/60 1 x 230 V, 50/60 Hz H [m] 6 5 4 3 2 1 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Q [m³/h] P1 [W] 50 40 30 20 10 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Q [m³/h] TM05 5403 3612 Speed P1 [W] 1/1 [A] Connections: See nsulating kits, page 13. Min. 7 0.06 System pressure: Maximum 10 bar. Max. 48 0.42 Liquid temperature: 2-95 C (TF 95). The pump incorporates overload protection. B3 H3 G H4 Type UPS2 P/N: 230V ~ PC:1251 50/60 Hz GB L1 1/1(A) P(W) P42 0.42 48 0.06 7 Max. Min. TF95 Max.1.0 MPa EE 0.23 / Part2 B1 B2 H1 H2 TM05 5202 3612 Dimensions [mm] Weights [kg] Ship. vol. Pump type EE L1 B1 B2 B3 H1 H2 H3 H4 G Net Gross [m 3 ] UPS2 15-40/60 0.23 130 79 47 75 28 102 60 76 1 2.5 2.7 0.004 0.23 130 79 47 75 29 102 60 76 1 1/2 2.7 2.9 0.004 UPS2 25-40/60 0.23 180 79 47 75 29 102 60 76 1 1/2 2.7 2.9 0.004 UPS2 PH-40/60 0.23 - - - - - - - 76-1.7 1.9 0.004 10
6 UPS2 15-50/60 130, UPS2 PH-50/60 1 x 230 V, 50/60 Hz H [m] 6 5 4 3 2 1 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Q [m³/h] Performance curves and technical data P1 [W] 50 40 30 20 10 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Q [m³/h] TM05 5403 3612 Speed P1 [W] 1/1 [A] Connections: See nsulating kits, page 13. Min. 7 0.06 System pressure: Maximum 10 bar. Max. 48 0.42 Liquid temperature: 2-95 C (TF 95). The pump incorporates overload protection. B3 H3 G H4 Type UPS2 P/N: 230V ~ PC:1251 50/60 Hz GB L1 1/1(A) P(W) P42 0.42 48 0.06 7 Max. Min. TF95 Max.1.0 MPa EE 0.23 / Part2 B1 B2 H1 H2 TM05 5202 3612 Pump type Dimensions [mm] Weights [kg] EE L1 B1 B2 B3 H1 H2 H3 H4 G Net Gross Ship. vol. [m 3 ] UPS2 15-50/60 0.23 130 79 47 75 29 102 60 76 1 1/2 2.7 2.9 0.004 UPS2 PH-50/60 0.23 - - - - - - - 76-1.7 1.9 0.004 11
6 Performance curves and technical data UPS2 25-80 180, UPS2 32-80 180 1 x 230 V, 50/60 Hz TM06 2044 3415 Speed P1 [W] 1/1 [A] Connections: See nsulating kits, page 13. Min. 11 0.1 System pressure: Maximum 10 bar. Max. 140 1.1 Liquid temperature: 2-95 C (TF 95). The pump incorporates overload protection. B3 B4 L1 B5 L2 L3 H1 H2 TM062103 3714 Pump type Dimensions [mm] Weights [kg] EE L1 L2 L3 B3 B4 B5 H1 H2 G Net Gross Ship. vol. [m 3 ] UPS2 25-80 0.23 180 22 141 95 50 64 27 112 1 1/2 2.7 2.9 0.005 UPS2 32-80 0.23 180 22 141 95 50 64 27 112 2 2.7 2.9 0.005 12
UPS2 7 7. Accessories nsulating kits UPS2 pumps can be fitted with two insulating shells. The insulation thickness of the insulating shells corresponds to the nominal diameter of the pump. The insulating kit, which is tailored to the individual pump type, encloses the entire pump housing. The two insulating shells are easy to fit around the pump. Union and valve kits UPS2 pumps can be fitted with ALPHA compatible unions, see the list below: ALPHAx Connection Product numbers, unions Rp 3/4 1 1 1/4 1 1 1/4 15-xx* G 1 25-xx G 1 1/2 529921 529922 529821 529925 529924 32-xx G 2 509921 509922 R Accessories * When ordering for UK versions, use the product numbers for 25-xx (G 1 1/2). Available on request. Fig. 16 nsulating shells Pump type Product number nsulating shells 505821 ALPHA plugs TM05 8315 2517 Thread types G-threads have a cylindrical form in accordance with the EN-SO 228-1 standard. R-threads have a conical form in accordance with the SO 7-1 standard. n the case of a thread of size 1 1/2", for example, the threads are specified as G1 1/2 or R1 1/2. Male G- threads (cylindrical) can only be screwed into female G-threads. Male R-threads (conical) can be screwed into female G or R-threads. See fig. 18. 1 2 3 TM05 3073 0612 Rc Rp R Rp R R Rp Rc Fig. 17 ALPHA plugs Pos. Description Product number 1 ALPHA plug, standard plug connection 98284561 2 3 ALPHA angle plug, standard angle plug connection ALPHA plug, 90 bend, including 4 m cable 98610291 96884669 Grundfos offers a special cable with an active built-in NTC protection circuit, which will reduce possible inrush currents. To be used in case of e.g poor quality of relay components that are sensitive to inrush current. G Fig. 18 G-thread and R-thread TM06 9235 3817 13
8 UPS2 Product range 8. Product range Note: Click on the product number and go directly to the performance curve in Grundfos Product Center. UPS2 Pump type Port-to-port length [mm] Connection Voltage [V] 50/60 Hz Product number UPS2 15-40/60 130 G 1 98243667 UPS2 25-40/60 130 G 1 1/2 98243668 UPS2 PH-40/60 - - 230 98334567 UPS2 25-80 180 G 1 1/2 98707853 UPS2 32-80 180 G 2 98707855 Data sheet Page 10 12 UPS2, United Kingdom Pump type Port-to-port length [mm] Connection Voltage [V] 50/60 Hz Product number UPS2 15-50/60 130 G 1 1/2 98334549 UPS2 PH-50/60 - - 98334563 230 UPS2 25-80 180 G 1 1/2 98707848 UPS2 32-80 180 G 2 98707851 Data sheet Page 11 12 UPS2, reland Pump type Port-to-port length [mm] Connection Voltage [V] 50/60 Hz Product number UPS2 25-50/60 130 G 1 1/2 230 98568293 11 Data sheet Page UPS2, BU/RO/GR Pump type Port-to-port length [mm] Connection Voltage [V] 50/60 Hz Product number Data sheet Page UPS2 25-40/60 180 G 1 1/2 230 98633963 10 14
9 UPS2 Grundfos Product Center 9. Grundfos Product Center Online search and sizing tool to help you make the right choice. http://product-selection.grundfos.com "SZNG" enables you to size a pump based on entered data and selection choices. "REPLACEMENT" enables you to find a replacement product. Search results will include information on the following: the lowest purchase price the lowest energy consumption the lowest total life cycle cost. "CATALOGUE" gives you access to the Grundfos product catalogue. "LQUDS" enables you to find pumps designed for aggressive, flammable or other special liquids. All the information you need in one place Downloads Performance curves, technical specifications, pictures, dimensional drawings, motor curves, wiring diagrams, spare parts, service kits, 3D drawings, documents, system parts. The Product Center displays any recent and saved items - including complete projects right on the main page. On the product pages, you can download installation and operating instructions, data booklets, service instructions, etc. in PDF format. Subject to alterations. 15
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